TURBINE QUESTIONS AND ANSWERS

Q. What is vacuum?
Ans. The vacuum can be defined as a state of very low pressure or we can say that a
space of no matter. It is below the atmospheric pressure and measured in (mmHg).
Q. What is the effect of high vacuum in Turbine?
Ans. We can't maintain very high vacuum in steam turbine because,
a) Turbine last stage is designed with 12% wet steam ,very high vacuum will lead to
increase wetness in last stage so it will reduce the mechanical strength of turbine last
blade as the volume of steam increase.
b) Due to high wetness corrosion of last blade will increase.
c) The condensate water will goes to under cooling due to low saturation pressure so
more coal and sensible heat required to rise the temperature of condensate.
d) Due to high vacuum condenser tube may be compressed.
Q. What is the effect of low vacuum in a steam turbine?
Ans. By maintaining vacuum in a turbine the work done of turbine will be increase
because vacuum will reduce the back pressure of the turbine hence there is more
pressure difference in between the turbine and more work done.Vacuum helps to
convert of steam to water by providing low saturation temperature.
Q. What is gauge pressure and absolute pressure?
Ans. Absolute pressure :- It is the pressure which is zero-referenced against vacuum.
The absolute pressure = gauge pressure + atmospheric pressure.
Gauge pressure :- It is the pressure which is zero reference to atmospheric pressure.
Gauge pressure = absolute pressure atmospheric pressure.
Q. What is Electro - Hydraulic governing control of turbine?
Ans. Now a days most of the turbine speed is controlled through this type of governing.
It is the governing system in which the turbine speed is controlled by electrical sensing
and hydraulic control. This type of governing provides very faster speed response than
the other governing. The turbine speed is measured through a electrical speed transducer
mounted on the HP end of the turbine rotor.
Q. What is eccentricity of steam turbine?
Ans. It is defined as the deviation between the center axis of the shaft to outer diameter
of the turbine rotor .This happen due to uneven cooling of turbine after shutdown
condition. Due to this effect the shaft may be got permanent damage and the fixed blade
may touch to moving blades. The eccentricity is measured when the turbine speed is
<240 rpm .
Q. What is the NAS value of oil ?
Ans. The NAS stands for National Aerospace Standard, is used to find the
contamination of oil. The NAS value is maintained 6 for turbine oil servo-46.The water
concentration of oil should not exceed more than 300 ppm.
Methods of oil sampling:- The oil sample is always taken from a upward pipe with
continuous flow. The sample taken between the pump and filter.
Q. What is diaphragm of a steam turbine?
Ans. The diaphragm is used in steam turbine to prevent leakage steam passing through
fixed and moving blades. It is the partition in between the fixed blade and moving blade
of steam turbine. Generally labyrinth seals are used for diaphragm. One half of
diaphragm is fitted into the top casing and another half is fitted into the bottom casing.
It works as a seal in between fixed and moving blade. It increase the turbine efficiency.
BOILER QUESTIONS AND ANSWERSQ. What are the heat transfer mediumsAns.
There are generally three medium as,a) Conduction:- Here the heat is transferred
through molecules. The molecules move from one part to another part of the substance.
Liquid are the good conductor where as vapor and gaseous are poor conductor of
conduction medium.b) Convection: - Here the heat is transferred through movement of
heated medium. The heated medium moves from one place to another place due to
density difference. This medium is used in boiler furnace.b) Radiation: - Here the heat is
transferred through gasses or vacuum. The heat transfer depends on the fourth power of
bodys absolute temperature.Q. What is boiling?Ans. There are two boiling process used
in medium heating.a) Nucleate boiling: - Here the heat added in such a manner that the
heat received from the inner wall of the container and the droplets are individually
converted into steam bubbles. As the bubbles grow the size they move to upward due to
lighter density. Other bubbles take their space and the process continues till the
container heated.b) Film boiling: - This is called film boiling, because a bubble film is
created at the inner surface of the container. If the heat flux added is greatly increase to
a certain value the bubbles are adjacent to each other instead of detached and a film is
formed at the inner wall of the container. This bubble film act as a poor conductor of
heat. The bubbles get super heated and finally increase the temperature of container and
may lead to failure of container / tube. The deviation of boiling process from nucleate
boiling to film boiling is known as departure from nucleate boiling (DNB).Q. What are
the circulations are used in boiler?Ans. There are three types of circulation is generally
used in boiler as,a)Natural circulation:- This circulation happen due to density
difference of the two medium. In boiler the two medium are water and steam, as steam
is lighter than the water it pushes to upwards flow of water steam mixture, the steam is
separated in drum and water comeback through down comer to again water wall. This
circulation use thermo- siphon principle. This circulation limited to operating pressure
below 175 kg/cm.b) Assist circulation:- In this circulation the medium moves through a
mechanical pump. The pump overcome the frictional loses in the tube. This type of
circulation used pressure beyond 175 kg/cm .The pump is placed in between the down
comer and bottom ring header of water wall.c) Forced circulation / once through
system:- This system used in boiler above critical pressure. Here the feed water is
directly fed from the beginning of the circuit to end of the circuit without circulation.
No drum used in this system. Super critical boilers are designed for once through
system.Q. What are the types of boiler?
Ans. There are two types of boiler is generally used,
a) Water tube boiler:- Here water is flowing through the tube. The hot gasses pass
through tube and heat transfer takes place. Now a days most of boiler are water tube
boiler.
b) Fire tube boiler:- Here hot gas passes through the tube and tube is immersed with
water. Heat transfer takes place from the hot flue gasses and steam is collected from top
of cell. This boiler used in for small steam demand. The solid combustible hot gas settle
inside the tube which reduce heat transfer.
Q. What are the types of economizer is used in boiler?A . There are two type of
economizer used in boiler as,a) Steaming economizer:- Here some of the water is
converted to steam and the steam-water mixture flows through the economizer. This
type of economizer used in high percentage of feed water to avoid scaling inside the
tube.b) Non-steaming economizer:- In this type of economizer only water flows through
the circuit.
Q. What is the draft and types of draft used in boiler?Ans. The draft is defined as
pressure difference in between a system. There are generally three types of draft used in
boiler,a) Forced draft: - Here force draft (FD) fan is used to maintain the draft in boiler.
Here the draft inside the boiler would be always positive draft.
b) Induced drought: - Here induced drought (ID) fan is used to maintain the draft in
boiler. The pressure inside the boiler would be always negative.c) Balance drought:-
Here both FD and ID fan is used to maintain the drought inside the boiler. The drought
at the tip of the burner will be zero. This type of drought is used in maximum boiler.
Q. What is super critical boiler?A. The boiler which works the pressure above the
critical pressure is known as super-critical boiler. This boiler works in the principle of
once through system. There is no drum only separator is used for separating steam from
water during partial loadAND ANSWERS
Q. What is (HGI) Hard Grove Index of coal?Ans. It is the measuring unit through which
the hardness of coal can be determined. Higher value of HGI means coal can be easily
grinded. The HGI of lignite coal is up to 120 where as the HGI of bituminous coal is 45
to 60 so lignite coal can be easily grinded than bituminous coal. The HGI is inversely
proportional to grinding power.
Q. What are the factors affecting for a coal mill performance?
Ans. This depend on the no of factors such as,
a) Grindability index of coal.
b) Fineness of coalc) Moisture content of the coal
d) Size of raw coal.e) Mill component wear.
Q. What are the advantages of (PF) pulverized coal fired boiler than the other boiler?
Ans. Here is the advantage of using pulverized coal fired boiler as,
a) Pulverized coal burners act like gas so the fire can be easily controlled.
b) Cheaper low grade coal can be burnt easily.
c) High combustion efficiency.
d) Load can be varied quickly.e) Quick and smooth light up of boiler.
f) Flexibility in firing to meet fluctuating load.
Q.What is soot blowers and their types?
Ans. The soot blower is a equipment through which the deposition of soot in boiler is
removed. There are two types of soot blower is generally used,
a) Steam inject soot blower:- Here the steam is used as the cleaning medium. The steam
flow through a pipe and nozzle, strikes at the surface of tube and removes the soot. Here
three soot blowers are generally used as i) long retractable soot blower ii) Wall soot
blower iii) Rotary soot blower.b) Sonic soot blower: - This type of soot blower is used
to remove soot by using low energy and high frequency sounds. They produce non-
destructive sound waves which hit at the surface of tube wall and remove the deposited
soot. By using this type of soot blower erosion and corrosion of tube can be avoided.
Steam loss can also be avoided. The frequency of sound in this type of soot blower is
ranging from 60 HZ to 350 HZ.Q. what is the effect of soot deposits in a boiler?
Ans.a) The deposited soot act as a poor conductor of heat which reduce the heat transfer
rate and increase flue gas temperature.b) The deposits block the flue gas path which
increase the drought loss.c) The deposit may lead to corrosion.d) Due to falling of large
size of soot it damage the tube in dry ash conveying system.
Q. What are the methods are used for steam temperature control in boiler.
A. We can control steam temperature by,a) Using gas recirculation method-Hot flue gas
is circulated for maintain steam temperature.
b) By providing excess air- By providing excess air it reduce the furnace temperature
for some timing hence control temperature.
c) Burner tilting method- Here the tilting of burner are provided by a pneumatic
cylinder. The burner can be tilted 30 up and down for control temperature.d)
Attemporation control-This is the best method for temperature control in boiler. Here
the attemporator are provided to spray water in steam in steam pipe line. Ceramic
thermal sleeves are provided to avoid thermal shock due to temperature difference of
steam and spray water.
e) Elevation of fuel firing The temperature is controlled by choosing upper or lower
elevation of fuel burner.TURBINE QUESTIONS AND ANSWERS
Q. what are the Turbine losses?A. Here are the turbine losses are defined as,
a) Tip leakage loss: - This loss is happen due to small amount of steam passing in
between the clearance of fixed blade and moving blade. The labyrinths are provided for
sealing of fixed and moving blades. Some steam passes through this labyrinth clearance
without any work done.
b) Disc windage loss:- This is the friction loss due to the surface friction created on the
disc.
c)Secondary loss:- This loss is due to friction on the casing wall and tip of the blade.d)
Wetness loss:- The turbine is designed for 12 % of exhaust steam. If the wetness of
steam increase id absorb the energy due to water droplets and second thing is it make
erosion at the last stage of the blade.
E) Loss due to lancing wire:- As the lancing wire is provided at the last stage of turbine
blade to provide mechanical strength , the production of losses in blade efficiency
because of passage area they block.Q. What is the function of a condenser in turbine?
Ans.
:-It save the DM water as the steam is converted to water and reuse.
:- It provide high vacuum so that heat rejection takes place from steam to water.
:- It give space for storage of condensate.Q. What is dummy / balancing piston in steam
turbine?
A . It is one part of the turbine used to neutralizing the axial thrust of turbine rotor.As
the pressure drop at each stage of turbine blade it produce axial thrust at the same
direction of steam flow. So it is necessary to balance the shaft. It is placed before the
first stage of turbine. This is fixed with the turbine shaft. The steam enter in between
the balance piston and first stage of turbine and give a reaction force to the balancing
piston opposite to the axial thrust hence it counter balance the turbine shaft.The
diameter of the balancing disc is designed in a such manner is that it can oppose the
force acting on turbine shaft.
Q. What are the types thrust bearing are used in rotating machineA. There are generally
four types of thrust bearings are used as,a) Tapered bearing.b) Babbitt faced bearing.
c) Tilting pad bearing.d) Roller bearing.
Q. What is the critical speed of turbine.
A. It is the speed at which the natural frequency of turbine shaft is close/near to the
operating frequency of the shaft. The turbine shaft material has its own natural
frequency, when we rotate the turbine rotor at some speed the both frequency are near
equal so it produce a high vibration and noise at this particular frequency. To avoid
critical speed we have to accelerate the turbine speed if the turbine speed hold at this
frequency then a high vibration occurs in the shaft. The value of critical speed is defined
by the designer of turbine. For example we can say that critical speed of a 150 MW ,
3000 rpm steam turbine may be 1800 rpm , 2200 rpm and 2500 rpm.
Q. What are the couplings used in steam turbine.A. There are three types of coupling are
generally used as,a) Flexible coupling:- This couplings are used where there is small
misalignment and axial movement of shaft .This coupling require lubrication.b) Semi
flexible coupling:- These couplings are generally used in between turbine and generator.
No lubrication require for this coupling.
c) Rigid coupling:- This couplings are provided in between the cylinders such as in
between HP- LP and between LP- IP
TURBINE QUESTIONS AND ANSWERSQ. Why turbine kept in turning gear after
shutdown?
A. To avoid hogging (bending downwards) or sagging (bending upwards) effect of
turbine turning gear is used after shutdown . There is a temperature difference in lower
casing and upper casing of turbine after shutdown if we kept turbine shaft stationary
then it will bent turbine rotor, to avoid this the turbine should be rotate in slow speed.
There are generally three type of turning gear used ,a) Electrical turning gear
Electrical motor is used in this type of turning gear to rotate the turbine less than 30 rpm
. A reduction gear is used to reduce the speed.
b) Hydraulic turning gear- In this system a hydraulic turbine wheel is mounted on the
shaft of the turbine. High velocity oil is supplied from jacking oil pump which rotate the
blade of hydraulic turning gear hence the turbine rotor. This system will start after the
starting of JOP. Most of advanced turbine use this system.c) Hand barring system If
the electric or hydraulic system fails then hand barring is done with slow speed through
a lever and handle.
Q. What is turbine stress evaluator (TSE)?A. It is the instrument used to online monitor
of turbine mechanical stress. It calculate the temperature difference of turbine upper and
lower casing. It is the algorithm system based on the comparison of actual calculated
stress.
Q. Why gland steam system is provided in steam turbine?A. The main function of gland
sealing system is , it prevent the escape/leakage of steam at the HP side of turbine and
prevent the ingress of air at the LP side of turbine. It is provided at the turbine shaft.
Labyrinth seals are generally used for sealing purpose. It is generally made of
aluminum, bronze and mild steel. Radial and axial clearance is provided in between the
seal. Steam throttled in every stage and gain kinetic energy at the expense its pressure
energy. So pressure dropped in every stage and it provide sealing of shaft. By providing
the labyrinth clearance very small the loss can be minimized. Collecting pockets are
provided at other end of sealing in which the steam can be collected and can be used in
gland steam blower.
Q. What is the differential expansion of steam turbine?A. It is the difference of
expansion in between the turbine shaft and turbine casing. The thermal emanation of
rotor is happen because of mass of casing is more than the mass of rotor. This is happen
due to sudden loading of turbine or rate of steam inlet in turbine is very high. If the rotor
expansion is more than casing then it is known as positive explanation and if the casing
expansion is more than rotor is known as negative expansion .The expansion value for
turbine tripping is generally provided as +- 6 mm. It is measured by LVDT ( linear
variable differential transducer).The differential expansion = Change in shaft length into
change in turbine casing length.Q. What is axial shift of turbine?
A. The axial shift of turbine can be defined as the physical shifting of turbine rotor from
the center point. This shifting is happen due to thrust on blade of rotor. Thrust tapered
bearing is provided to prevent the axial shift of rotor. The tripping value for turbine
axial shift is generally provided with +- 0.6 mm. The possible causes of axial shift is
due to,a)Sudden drop in vacuumb) Sudden drop in steam temperaturec) Sudden change
in load
d) Sudden closer of extraction NRV.
e) Lube oil failure in thrust bearing.
f) Scaling in turbine blades.Q. What is TSE (turbine supervising panel)?A. This is the
integrated combine logic provided to observe the safe operation of turbine. This
supervisory panel observes,
a) Turbine casing explanation during roiling.b) Turbine differential expansion.
c) Turbine rotor eccentricity.
d) Turbine vibration.
e) Rate of loading of turbine.
Q. What is over speed of turbine?
A. It is the increased speed of turbine due to grid failure or islanding condition. Over
speed happen due to sudden unloading of turbine. The over speed of turbine tripping is
generally provided with speed > 110 % of rated speed. The machine should not be
allowed to cross that limit. The over speed tripping can be provided by a over speed
governor or mechanical governor.
Q. What is turbine tripping condition?A. A turbine may be tripped due to this reasons,
a) Boiler trip/generator trip
a) Due to over speed- >110 %b) High axial shift - +- 0.6 mm.
c) High differential expansion - +- 6 mm.
d) Condenser vacuum very low - < 0.6 kg/ cm
e) Main steam temperature low - <485 deg c.f) Main steam temperature high - > 565
deg c.
g) Press of emergency push button.
h) Main steam pressure and temperature low low and high high.
i) Turbine bearing temperature high- >120 deg c.g) Turbine vibration high - > 165
micron.
h) Turbine lube oil temperature high - >65 deg c.
i) Mot oil level low - < 30 %.
j) Malfunction of sensing device.

BOILER QUESTION & ANSWER

Q . What is steam trap and it's function?
Ans. function of steam trap- It is a device is used in steam pipe line to discharge
condensate and gasses, prevent to escape of steam through the line. It ensures that steam
is not wasted. This is a self contained valve which automatically drains the condensate
from a steam containing device. This is generally provided in steam drains or before
steam drain valve.
You tube video of mechanical steam trapTypes of steam trap:-
1> Mechanical trap Works in the principle of difference in density between steam and
condensate. This type of trap operate according the condensate level in the port if the
condensate level increase the float operates and allow to condensate pass through the
pipe ,when condensate level decrease is close the valve and doesnt allow the
condensate. Types of mechanical trap i) Float type, ii)Float with lever type, iii)Inverted
bucket type, iv)Open bucket type.
2> Thermodynamic type steam trap - Works in the principle of difference in between
thermodynamic property of steam and condensate.This types of traps operate due to
velocity change in flow of compressible and non compressible fluids.As the steam starts
condensate there is a temperature difference which allow the trap to operate. Types of
Thermodynamic type steam trap i) Disc type ii) orifice type.3> Thermostatic type steam
trap- This trap works in the principle of difference of temperature in between steam and
condensate. Types of Thermostatic type steam trap i) Bimetallic type, ii) Metallic
expansion type.Q. What is (NRV) Non Return Valve?A. This is also known as one way
valve which allow the fluid flow in one direction only. As its name implies non return
means there is only one direction flow.All the assembly are provided with a valve
bonnet.This valves are generally used in pump discharges and steam water pipe
lines.This device ensures there is no back flow of fluid from the source. It has two lines
one is inlet line and other is outlet line.There is a direction symbol provided on the
valve which show the direction of flow fluid.Types of NRV:-i> Tilting disc check valve-
This is a disc type check valve.The disc provided fixed with a hinge which swing up
and down. As the fluid flow in the line it lift by the fluid force and allow the fluid to
flow in the pipe . When there is no fluid flow in the circuit it closes due to gravitational
force.
ii> Ball check valve- Here a spherical ball is used to fervent the fluid flow. The ball is
spring loaded which close the valve when there is no fluid flow in the line. The pressure
of fluid lift the ball and let the fluid to flow.iii> Diaphragm type NRV This is consists
of a rubber diaphragm clapper ,Which works on the differential pressure When the
pressure in the upstream is more it open the diaphragm and allow the fluid to flow and
when the pressure is equalize is closes diaphragm and prevent to fluid.iv> Stop check
valve- Its construction is same as the swing check valve except that here is a external
control mechanism of handle or lever provided.v> Lift check valve- Here a lift or disc is
provided which operates on the working pressure of the fluid.Q. what is Pressure relief
valve(PRV) ?A.
Image of pressure relief valve.
The relief valve (PRV) is a type of valve used to control or limit the pressure in a vessel
or system during an overpressure of the system. The primary purpose of a pressure
Relief Valve is protection of life and property by venting fluid from an over pressurized
vessel. Many electronic, pneumatic and hydraulic systems exist today to control fluid
system variables, such as pressure, temperature and flow. Each of these systems requires
a power source of some type, such as electricity or compressed air in order to operate. A
pressure Relief Valve must be capable of operating at all times, especially during a
period of power failure when system controls are nonfunctional. The PRV is provided
on the on the main steam line to control the line pressure. The PRV is generally operated
through pneumatic pressure.The PRV operated according to the set pressure of rhe
controller. The valve set down when the pressure reach to normal value.Q. What is the
difference between safety valve and pressure relief valve?A. Difference between safety
valve and relief valve
Relief Valve The relief valve is used on a filled vessel. For such a valve the opening is
proportional to increase in the vessel pressure. Hence the opening of valve is not
sudden, but gradual if the pressure is increased gradually. A relief valve is meant to
relieve pressure to prevent an over pressure condition. A relief valve may have an
operator on it to assist in opening the valve in response to a control signal. The capacity
of PRV are generally small.
Safety Valve This device is used to relief on a compressible filled vessel. For such a
valve the opening is sudden. When the set pressure of the valve is reached, the valve
opens almost fully. A safety valve is meant to relieve pressure without operator
assistance and a safety valve, or combination of safety valves, must be have a capacity
to relieve more than the energy input to the volume being protected.
procedure of boiler?Pre check up for cold start up of boiler :-
1) Check all maintenance work are completed and all permit are returned.
2) Check all foreign materials has been removed vfrom the pressure parts
3) Check all access doors are closed.
4) Check all equipments are trial run successfully.5) Check all interlock test and prior
test to startup are completed.6) Check no jamming in rotary equipment , lubrication oil ,
cooling water system is normal.
7) Check all the oil level meter are in operation.8) Check all the position of valve is
normal.
9) Check HFO & LDO pump are running in re circulation.
10) Fill the deaeretor with initial filling line.
Conform the position of the following valves:-
1) All blow down and drain valves on boiler and water wall should be closed condition.
2) All boiler and super heater filling valves are closed condition.3) Soot blower master
steam valve should be closed condition.
4) Main steam line stop valve should be closed condition.
5) De-super heater spray valve should be closed condition.
6) Drum vents should be open condition.
7) Super heater header drains should be open condition.
8) Fill the boiler with initial filling line and observe the water coming from the vent of
economizer, drum vents, and super heater vents sequentially.9) CBD and IBD drains
should be closed condition.
Start Boiler light up:-1) Start the (ACW) industrial cooling water system.2) Start the
instrument air compressor.
3) Start the APH motor it that is rotary APH.4) Put the auxiliary steam system (PRDS)
in operation for oil heating.
5) Start the ID and FD fan.
6) Start the scanner air fan.
7) Start the HFO/LDO pump with recirculation.
8) Adjust the fan speed and opening of dampers , increase the air flow up to 30% of
total air flow.
9) Maintain the furnace draft of approximately -4 mm.
10) Start boiler feed water pump and keep drum level as per purge permissive.
11) Make sure all purge permissive are satisfying and start purge for 5 minutes.
12) Start the oil burners by maintaining furnace draft.
13) Visually check the flame of the oil burner is that healthy or not.14) When prepare
for heavy fuel firing, be sure that atomizing steam is in service and oil temperature
reach to permissive value.
15) Change the position of oil guns on each elevation for uniform heating of furnace.
16) Increase the furnace temperature by 5 deg c per minute.
17) The firing should be continued nearly 08 hours.
18)Start the HP dosing pump with minimum stroke.
19) Observe the drum upper and lower metal temperature increase uniformly.
20) Close the drum vents when drum pressure reaches to 2 kg/cm2.
21) Observe the expansion reading of boiler within limit.22) Close the main steam line
vent when the pressure reaches to 5 kg/cm2.
23) Charge the auxiliary steam line and connect to common header if available.24)
Check all drains of the boiler should be closed condition.
25) Slowly open the main steam line bypass valve.
26) Observe all condensate removed from line and open slowly main steam valve to
turbine and observe hammering of steam line.
27)Charge the sample cooler line and ask D.M plant operator to check all the parameter
of water and steam.
Procedure of turbine cold startup?The startup condition of the turbine is considered as
per inner casing temperature of the turbine such as,
a) Cold start up If the casing temperature is < 200C.b) Warm start up - If the casing
temperature in between 200-300C.
c) Hot start up- If the casing temperature is > 450C.
Pre checklist for cold start up:-
1) Check all work completed and all permit is returned.
2) Confirm all interlock test of turbine is completed.3) Check all level gauges and
pressure gauges in operation.
4) Check cooling tower sump level should be normal level.
5) Check the oil level of MOT tank and control oil tank should be normal.
6) Check the generator cooling water and lube oil cooling system is normalized.
7) Check the compressor is system in running .
8) Check the ACW pump in running.
9) Check the circulating water pump(CW) in running.10)Check the turbine lube oil
pump is running and turbine is in barring gear.
11) Check the generator air cooling system is in operation.Procedure for turbine
rolling:-
1) Start the CEP with minimum re circulation.2) Start the gland steam system with
auxiliary PRDS.
3) Start the gland steam blower and normalize Gland steam drain system.4) Maintain
the gland steam temperature in between 121 to 177 deg c.
5) Start the vacuum pump or ejector for vacuum pulling.
6) Ensure the boiler develop rated pressure above 15 kg/cm2 & temperature >360deg c
7) Put the HP and LP bypass system in operation for line warm-up.
8) Ensure all turbine drains are open condition.
9) Check the turbine lube oil temperature is in-between 38-42 deg c.
10) Check the differential expansion and eccentricity is normal.
11) Reset the turbine from governor panel.
12) Press the latching or start bottom to open the ESV.
13) Give command for rolling of turbine.14) Check the turning gear and JOP
automatically stopped when speed reaches >300 rpm.
15) Press the hold button of turbine and hold the speed in 500rpm to check the
eccentricity < 0.076 mm, axial shift +- 1 mm and differential expansion +- 6mm of
turbine.
16) Continue the speed of the turbine with 40 rpm/min and speedup the turbine speed
during critical speed of 1850,2000 and 2200 respectively (as per designer).
17) Check the main oil pump comes in service and AOP is stopped condition.
18) After turbine reached to full speed hold for some time and ensure upper and lower
casing temperature difference is within limit.
19) Ask the electrical people for synchronization.20) Close all turbine drains after
synchronization.
21) Increase load by follow of turbine cold startup load curve.
22) When the load is increase to 20% of full load charge the Extraction line gradually.
23) Finally check all parameter of turbine is ok and increase turbine load to full.

TURBINE QUESTION & ANSWER

Q. What is the function of ejector in condenser and its working principle ?Ans.
Function of ejector:- The main function of the ejector is to extract air and no condensate
gasses from a closed system . It removes air from the condenser and provide vacuum.
The amount of air extracted at the time of starting is more as compared to running unit.
Parts of ejector:- It generally consists of converging nozzle , diverging nozzle , diffuser
throat , inlet and outlet pipes, Rota meter for measurement of air flow , cells with tube
for regeneration heat transfer , Steam traps for drip control .parts of a steam
ejectorWorking principle of ejector :- When a high pressure motive fluid( steam/liquid)
enters the steam nozzle , this result in a decreasing pressure and increasing velocity of
the fluid again the fluid enters in the diffuser which result in a increasing pressure and
decreasing velocity of the fluid so due to pressure difference vacuum is created in
between the nozzle and diffuser we can say venture throat . So due to pressure
difference or vacuum it sucks no condensable air and fluid from the system. The
mixture then enters to an inter condenser where the steam is condensate. The inter
condenser are designed with a special inter condenser baffles of tubes where heat
transfer takes place . The second stage ejector handles the non condensate gasses of first
stage ejector and through a vent opening to the atmosphere. The air flow can be
measured by the rota-meter. The condensate water of steam send back to re use through
steam traps.
Types of ejector :-There are generally two types of ejector generally used as ,i > Hogger
ejector :- This ejector is known as the starting ejector which is used to pull the gasses at
the time of starting of system. It has high capacity of air extraction. This ejector
operates with parallel with the running ejector till the vacuum reaches 500-600 mm of
HG column , then the hogger ejector is switched off and main ejector will remain in
service. The main disadvantages of this ejector is the steam escaped to atmosphere and
can't reuse.Image of a main ejector
ii> Main ejector :- This is also known as the running ejector which evacuate the air
continuously at the system running condition. This is a multi stage type ejector . The
high velocity air -water mixture enters to the shell and cooled in the first stage of the
shell by condensate. Steam is thus condensate and the steam air mixture volume reduced
and allowed to second stage of the nozzle . In the second stage the mixture is
completely condensate and the air is vented to the atmosphere. The drains are provided
with loops or siphoned to prevent ingress of air from the atmosphere.Here the
condensate seam is again recovered in condenser and reuse.What is Vacuum pump or
liquid ring air pump used in condenser and it's working principle ?As the steam ejector
use steam for air evacuation this is a loss for the plant as the pressure and temperature of
the steam is reduced to the rated parameter of the ejector , so now a days in modern
power plants rotary air pumps are used for air extraction purpoes.The rotary air pump is
more flexible as it doesnt depend steam and water circuit for air
extraction.Construction: - Its construction is same like a centrifugal pump with multiple
impellers. It consists of impeller, suction pipe , discharge pipe. Diffuser, divergent cone,
fixed guide nozzle . The impeller with a blade is attached to a center hub located in a
cylindrical body. The pump require liquid to create vacuum. A tapping is provided at the
top of the pump for air line connection.
Image of rotary liquid ring air pump
Working principle:- The liquid if fed to the pump through suction pipe , due to rotary
motion of the pump impeller a centrifugal force is created in the impeller of the pump. It
consists of a multi-bladed, rotating element (impeller), eccentricity positioned within a
cylindrical casing. The compression of the gas occurs in one or two impeller stages
depending on the ultimate vacuum required, although for this service two/multi stage
pumps are generally required. Water or some other in-compressible fluid, called service
liquid, is introduced to the LRVP. As the impeller rotates, a ring of liquid is formed
inside the pump casing from centrifugal force. This action draws the gaseous stream
into the pump through the inlet port. The gas is compressed by the liquid ring, exiting
the first stage through a smaller area discharge port and into the second stage of the
pump. The second stage is volumetrically smaller doing the final compression of the
gas. The gas then exits the pump usually at atmospheric pressure, along with the service
liquid.Only small amount of water makeup required due to water leakage or
evaporation.
uses of liquid ring pump:-1) Power generation equipment (produce vacuum).2)
Petrochemical.
3) Seawater deae-ration.
4) Pharmaceutical.
5) Ground water remediation/vapor extraction.
6) Food production.
Advantages of liquid ring pump:-These pumps can easily take care of condensable
vapors and can even handle fluids of various kinds without affecting the performance of
the pump. Based on liquid ring technology, pumps have only one rotating or prime
functioning part and therefore are economical and much easier to maintain than the
other pumps. The repairing or rebuilding of these pumps is very easy in comparison to
other complicatedly designed pumping units. Liquid ring vacuum pumps can efficiently
be employed as vacuum jobs and also for the compression tasks as well which usually is
not possible with ordinary pump sets.Quick starting also another advantage of this
pump.
What is Burner Management System (BMS) and its function?The main function of
Burner Management System (BMS) is to protect boiler from explosion as it ensures a
safe, orderly operating sequence in the start-up and shutdown of fuel firing equipment
and to reduce possible errors by following the sequential and safe operating procedure.It
is a digital logic system, which provides status information and monitoring of the firing
equipment ensuring a safe orderly operating sequence during the start-up, continuous
operation and shutdown of the fuel firing equipment, and prevents any errors of
commission or omission as a result of the various permissive and safety interlocks of
satisfied operation.The system also protects against malfunction of fuel firing
equipment and associated systems .BMS provides permissive interlocks only to ensure
safe startup of equipment. Once the equipment is in service, the operator must follow
acceptable safe operating practices.The BMS supervises, controls and monitors the
preparation, distribution and admission of fuel and air into the furnace.The primary
function of the BMS components is to prevent the formation of an explosive mixture of
fuel and air from accumulating within any portion of the boiler.Major furnace
explosions can result from the ignition of un-burned fuel accumulated within the
furnace in only one to two seconds. Operator reaction time is inadequate to respond
quickly enough to prevent dangerous situations from occurring. The safety systems
incorporate many permissive and interlocks which allow the operation of equipment
only after certain conditions have been satisfied. Much of the logic has been derived
from established operating procedures which have been proven safe over the years in
fossil fuel fired plants.
The Burner Management system is a constant monitor of many points of operation and
reacts almost instantly to malfunctions of equipment or potential problems. It provides
the operator with a certain degree of security and alerts the operator to problems by
sounding an alarm in time for the operator to check the problem and, in most cases,
correct it before damage to the unit or a trip occurs.BMS logic configuration.CAUSES
FOR FURNACE EXPLOSIONS:-Here are the main causes of furnace explosion:-
a) Ignition of an accumulation of combustible gas in a boiler out of service.
b) Operating for a long period of time with a deficiency of air and then
suddenly bringing about proper air fuel ratio.
c) Improper sequence of operation of firing system components
d) Insufficient ignition energy supplied relative to actual requirements
e) Firing with improper air fuel ratio and insufficient furnace temperature.
Function of BMS :-
a) Prevent firing unless a satisfactory furnace purge has first been completed.b)Prohibit
start-up of the equipment unless certain permissive interlocks have first been completed.
c) Monitor and control the correct component sequencing during start-up and shutdown
of the equipment.d) Conditionally allow the continued operation of the equipment only
while certain safety interlocks remaining satisfied.
e) Provide component condition feedback to the operator and to the plant control
systems and/or data loggers.
f) Provide automatic supervision when the equipment is in service and provide means to
make a Master Fuel Trip (MFT) should certain unacceptable firing conditions occur.
g) Execute a MFT upon certain adverse unit operating conditions
Major Equipments Included in the BMS system:-
a) Pulverizes and Coal Feeders.b) Induced Draft Fans (ID Fans )
c) Forced Draft Fans (FD Fans)d) Fuel Oil Trip Valves.
e) Oil Burners system.
f) Scanner Cooling Air Fans.
g) Primary Air Fans (PA Fans )
h) Seal Air Fans (SA fans)

What is Boiler Master Fuel trip relay (MFT) ?

The boiler Master Fuel Relay Trip (MFT) provided to protect the boiler from any unsafe
operation condition in the boiler. Once MFT is initiated, The BMS will stop all fuel
supplied to the furnace. The All Fuel oil (LDO and HFO) trip valves will be closed, All
Pulverizes and Coal Feeder will be tripped along with Primary air and seal air fans.
The Boiler MFT will be initiated in following abnormal conditions:-
1) By Pressing Boiler Emergency push buttons together from the control desk.
2) Turbine trips after turbine reset.
3) Drum Level Hi Hi.
4) Drum Level Lo Lo.
5) Drum Press Hi Hi.
5) Main Steam Temperature Hi Hi At 555 deg. C.
6) Air flow less than 30% of total Secondary Air flow.
7) 2/3 Furnace Pressure Hi Hi.
8) Both ID Fans off.
9) Both FD Fans off.
10)Unit flame failure.
11) Loss of fuel.
Unit flame failure-
Operating boiler with unstable flame is lead to boiler explosion as accumulation of
unburnt carbon and gasses will be more. The unit flame failure happen due to sudden
reduction of fuel to minimum value,Malfunctioning of flame scanner,Air flow less than
30% of total air flow,loss of ignition energy,sudden closer of fuel air dampers.Loss of all
fuel-
Normally loss of fuel is activated after the boiler is lighted up or tried to light up (i.e.
any local fuel oil has opened once). After that if all burner fuel valves get closed, and all
feeders are off it will generate loss of all fuel OR All feeders are off, any burner oil
valve is open and main trip HFO/LDO not OpenWorking principle of pulverizing Bowl
mill ?
Bowl mill is a vertical spindle medium speed mill. In a bowl mill the coal is pulverized
between a disc called bowl rotated by the drive assembly called rollers .The rollers kept
above the disc loaded by springs or pneumatic or hydraulic loading devices.
Parts of bowl coal mill:- Mill base and body.
Gear box assembly.
Separator body.
Lubrication system.
Scrapper assembly.
 Roller and bowl assembly.
Mil discharge pipes.
Pirate discharge assembly.
Measuring instruments.Image of a coal mill
Construction of Bowl mill:-
The vertical drive shaft is accommodated in the mill base with a worm wheel keyed to it
and coupled by a motor.The speed reduction is provided by gear box assembly. One
thrust bearing below the worm wheel and two radial bearings one above and one below
worm wheel support the vertical shaft. The work wheel, worm shaft, worm shaft
bearing, vertical shaft thrust bearing and lower radial bearing, all housed in the mill
base, are flood lubricated by the oil filled in the mill base up to the worm wheel. The
upper radial bearing is lubricated by the oil pumped by a gear pump attached to the
vertical shaft through the bore drilled in the vertical shaft. This oil from the bearing
drains back to the sump through the oil cooler placed in the mill base. A view port with
a sight glass is provided on the oil
return line to monitor the oil flow. A blow assembly with scrappers is mounted on the
top of the vertical shaft. The surface of the bowl is lined with bullring segments made of
wear resistant material such as BIHARD, HICHROME etc. As the mill works under
pressure, to prevent the entry of dust laden air to the gearbox a sealing arrangement is
provided. When the bowl rotates, the seal runner moves over the bronze seal making a
metal to metal contact. The air seal housing is admitted with clean, cold seal air at a
pressure higher than mill pressure. With such an arrangement through the interface
clearance between rotating and stationary parts only the seal air can pass. Hot high-
pressure air called primary air is admitted to the mill sided assembly the bowl. The mill
side consists of insulation to prevent excessive conducting of heat from mill side to mill
base. It also has bottom liners to provide an enclosure for the scrappers of the bowl
assembly. The scrappers scrap the pyrites and rejects falling from the bowl on this zone
into the pyrite hopper through the tramp iron spout opening in mill base.There are two
pirate gate in hopper, The outlet gate will be opened only for emptying the pyrite hopper
after closing the inlet gate. The mill has three grinding roll assemblies, in each assembly
a grinding roll is suspended on a journal shaft which is fixed to the journal head.
Tapered roller bearing are provided inside the housing of journal shaft. Oil is filled in
the housings to lubricate the bearings. The rollers are centrifugally casted with the outer
surface made of material same as that of bull ring segments such as NIHARD,
HICHROME ETC. A turnion shaft is inserted through the journal head for placing the
roller journal assembly can swing over the turnions shaft. The roller journal assemblies
are mounted in such a manner that the roll face
is approximately parallel to and is in close proximity with the inside surface of the
grinding bowl. Stop bolts are provided to supports the journal head at the bottom.
Through these stop bolt the clearance between roller and bowl can adjusted. Pressure for
grinding is applied through compression springs mounted from above the roller journal
assembly. The tip of the spring willbe just in contact with the journal head. The
separator body encloses the roller journal assemblies and springs. The separator body
has liners at the bottom, which deflect the primary air entering the mill from the mill
side. An internal multivaned classifier connected to the mill outlet is located at the
bottom of the separator body top. The classifier vanes are externally adjustable. A
venturi is provided at the classifier outlet and classifier can be adjusted manually as per
requirement of coal size.
Working of bowl mill:-Coal from the raw coal feeder is fed at the centre of the bowl
through a raw coal inlet chute inserted at the center of separator body top. Due to
centrifugal force the coal moves towards the periphery. The three rolls exerts the
required grinding pressure through the springs. The primary air supplied to the mill side
moves up through the vanes around the bowl. B thedeflector liners the air is directed
towards the center of the mill which cause the reciruculation of the coal through the
grinding area. The air moving upwards picks the fine coal and enters classifier through
the vanes. The vanes introduce spin and as a result course particles get separated from
the stream and return through the annulus between the centre feed pipe andclassifier
cone to the bowl further grinding. Fine coal moves out with air through the multi-port
assembly at the outlet of the classifier. Any hard foreign material (Pyrites) entering the
mill with coal cannot be pulverized. Such particles when move on the bowl lift the roller
journal assembly compressing the spring and increasing the gap between roller and the
bowl. Once such particles clear the bowl the spring brings back the roller journal
assembly to the initial position. The Pyrites fall down from the bowl into the mill side
assembly where they are sweeped by the scrappers and discharged into the pyrite
hopper through the tramp iron spout. Periodically the rejects are removed from the
pyrite hopper by first closing the inlet gate and then opening gate.
The major advantages of this mill are:-
low power consumption.
Reliability.
Minimum maintenance.
Wide Capacity.
Quiet and vibration less operation.
Ability to handle a wide range of coal.
FACTORS AFFECTING MILL PERFORMANCE:-
Grind ability index of coal
Fineness of milled product
Moisture content
Size of raw coal
Mill wear
at is furnace purge and its necessary?
Necessary of furnace purge-
The furnace purge is one of the parts of Furnace safe guard and supervisory system
(FSSS) and is provided to remove incombustible gasses and un-burnt particles from
boiler before boiler light up. During boiler sudden trip there is accumulation of un-burnt
gasses in furnace , At the time of starting of boiler this gasses may cause of explosion to
avoid that furnace purge is provided.
30-40 %ge of air flow is provided in boiler by starting ID,FD fan and purging continue
for five minutes.
Cndition of furnace purge-1) Boiler shall be in trip condition
2) Drum level within operating range (not high, not low)
3) Either of the ID and FD Fans are in service
4) Purge airflow should be 30-40% of the full load airflow.
5) LDO Header trip Valve closed.
6) HFO Header Trip Valve Closed
7) All Pulverizer OFF.
8) ALL PA Fans OFF.9) All Pulverizer fuel oil valves Closed.
10) All Coal Flame Scanner sense no flame.11)All Oil scanner senses no flame.
Procedure of boiler purge:-
When the above purge permissive conditions are satisfied a "PURGE READY",
Indication will appear in DCS. By pressing the "PURGE START" button, furnace purge
will start which will be indicated by "PURGE IN PROGRESS. The furnace purging
will continue for 300 Seconds, after that "PURGE COMPLETE" indication shows that
purge has completed. Press "MFRRESET" Button which will reset master fuel trip relay
giving indication MFR RESET".
After MFT reset condition boiler is ready for light up.
What is the function of condenser in steam turbine & its type?
The main function of condenser is to convert gaseous form of exhaust steam into liquid
form at a pressure of below atmosphere or we can say that It is a heat sink in the thermal
cycle in which rejection of heat energy takes place on condensation of exhaust steam of
turbine. Cooling mediums are used such as water/air to convert steam into water. By
converting steam into water the back pressure of the turbine exhaust can be reduced and
due to pressure difference between inlet and outlet of turbine , there is more enthalpy
drop and more work done in the turbine. Back pressure of turbine is defined as pressure
at the exhaust nozzle of the turbine.
The main function of condenser:-
i)saving on steam require per unit of electricity
ii) To convert exhaust steam to water for reuse thus saving on deed water
requirement.
iii) Deaeration of make-up water introduced in the condenser.
iv) To form a convenient point for introducing make up water.
Image of surface condenser
Type of condenser:-
There are generally two types of condenser as
a) Direct contact (jet) condenser- Here cooling water and exhaust steam are mixed
together. The requirement of cooling water is very much less than surface condenser.
This is the best effective condenser but it has the disadvantage that cooling water quality
should be maintain properly.
b) Surface Condenser- This type of condenser is used in most modern steam turbines.
Cooling water flows through inside of tube and Condensation of exhaust steam takes
place on the outer surface of the tubes. The condenser essentially consists of a shell
which encloses the steam space. Tubes carrying cooling water pass through the steam
space. The tubes are supplied cooling water from inlet water box on one side and
discharged, after taking away heat from the steam, to the outlet water box on the other
side. Instead of one inlet and one outlet water boxes, there may be two or more pair of
separate inlet-outlet water boxes, each supplying cooling water to a separate bundle of
tubes. This enables cleaning and maintenance of part of the tubes while turbine can be
kept running on a reduced load. Manholes have been provided for routine maintenance
and visual inspection along with venting and draining arrangement for individual water
boxes. The tubes have been so arranged that there is equal distribution of steam on the
tube nest with minimum resistance to steam flow. In order to allow expansion along he
height, the condenser is supported on springs specially designed to take up load ,Springs
are provided at the bottom of condenser.
Working of condenser:-The exhaust steam flows from turbine exhaust through cooling
tube. Steam condensate to water and pumped through condensate extraction pump
(CEP).The cooling water return to cooling tower after heat exchange for cooling. An
ejector system is provided at the top of condenser to remove non condensate gases.
Scrubber mesh is provided near air extraction point of condenser to prevent carryover of
steam through no condensable gasses.
Materials for Condenser Tubes-Generally condenser tube material is designed in the
view of cost and cooling water quality. Copper alloys are Brasses, Cupro-
nickel,titanium grade-2 and Bronzes are generally used in most condenser. Stainless
steel tubes has also been used and has good corrosion resistance though heat transfer co-
efficient is quite lower than the copper alloys. Because of high cost, stainless steel is
used only where water is highly corrosive. Some sea side power plants are also using
Titanium despite high cost, because of highly corrosive environment.
deaerator and its working principle?
Necessary of deaerator:-
The presence of oxygen, and other non-condensable gases, in the feed water is a major
cause of corrosion in the feed water piping, boiler, and condensate piping line. The
dissolved oxygen content of the feed water is a major factor of corrosion in boiler. Low
pH levels in feed water cause severe acid attack throughout the boiler system.The
remove of desolved gasses and oxygen process is known as deaeration. There are two
types of deaeration is generally happen as chemical deaeration and mechanical
deaeration. The main function of deaerator is -
1)Removing the dissolved gases to prevent corrosion feed water heated.
2) Work as a feed water storage tank.
3) Increase thermal efficiency.
4) Provide required Net positive suction head to feed water pump.
Image of deaerator
You tube video of deaerator
Working principle of deaerator:-
a) by Henrys Law- Accordind to William Henry in 1803 it state ,that gas solubility in a
solution decreases as the gas partial pressure above the solution decreases.In simple we
can say that The solubility of any gas dissolved in a liquid is directly proportional to the
partial pressure of the gas. Solubility of gases decrease with increase in solution
temperature and or decrease
in pressure.
b) The second principle state that ,deaeration is the relationship between gas solubility
and temperature. Easily explained, gas solubility in a solution decreases as the
temperature of the solution rises and approaches saturation temperature.
Types of deaerator:-
a) Tray-type deaerator- It consists of over several rows of trays. Makeup water and
pumped returns are sprayed into the deaerator tray section through a stainless steel spray
nozzle. The spray nozzle provides a thin conical sheet of water that condenses the
vapors while permitting oxygen to exit through the vent. The partially deaerated water
then begins to cascade through the trays. The combined makeup and pumped returns are
heated with steam that flows upward through the stainless steel trays. The steam
vigorously scrubs the dissolved oxygen from the makeup and pumped returns. The
trapped returns enter the deaerator storage section. Steam from the returns also flows
upward through the deaerator trays, while the water drops to the water level in the
deaerator storage section. The fully deaerated water remains in the deaerator storage
section for use by the boiler, while the excess steam flows into the deaerator tray
section. Non-condensable gases enter the vent and pass to the atmosphere.
Image of plate type deaerator
b) Spray type deaerator- The spray-type deaerators do not use trays for dispersion of the
water. In this case, spring loaded nozzles located in the top of the unit spray water into a
steam atmosphere which is heated to within a few degrees of the saturation temperature
of the steam. Most of the non-condensable gases are released to the steam, and the
heated water falls to a water seal and drains to the lowest section of the steam scrubber.
The water is scrubbed by large quantities of steam and heated to the saturation
temperature prevailing at this point. The intimate steam to water contact achieved in the
scrubber efficiently strips the water of dissolved gases. As the steam-water mixture rises
in the scrubber, a slight pressure loss causes the deaerated water temperature to remain a
few degrees below the inlet steam saturation temperature. The deaerated water
overflows from the steam scrubber to the storage section below. The steam, after
flowing through the scrubber, passes up into the spray heater section to heat the
incoming water. Most of the steam condenses in the spray section to become part of the
deaerated water. A small portion of the steam, vented to atmosphere, removes non-
condensable gases from the system.
c) Vacuum type of deaerator- Here The oxygen-containing make-up water, preheated to
40-90 C, is led to the upper section of the deaeration tank. In order to optimize the
removal of oxygen, the deaeration tank is equipped with fillers for division of the water
into fine particles. The vacuum pump creates the necessary vacuum so that the make-up
water boils. When the water boils, the oxygen is liberated and removed by means of the
vacuum pump. The deaerated water is separated into two streams, which are pumped
partly into the district heating network, partly recycled over the deaeration
tank.Chemical reaction in deaerator during Hydrazine doosing-N2H4 + O2 = N2 +
2H2O
Gas +Water
3N2H4 = 4NH3 + N2
Additional ammonia reacts with
2NH3 + CO2 + H2O = (NH4)2CO3
(acidic) Ammonium Carbonate (Neutral)

How oil centrifuge works for oil purification work?

Introduction :-
The main function of oil centrifuge is to purify oil, remove moisture and non dissolved
solids from oil. It is most necessary to supply moisture free oil to Turbine shaft. In
Power Stations, Centrifuges are mainly used to separate moisture particles from
lubrication oil. They are connected with turbine main oil tanks. Two separation
processes viz. Purification and Clarification can be done in centrifuge. Purification is
the process of separation of two immiscible liquids having different specific gravities
and is useful for the removal of the solid particles with specific gravity higher than
those of the liquids. Clarification is the process of separation of solid particles from oil
or any other liquid.
Image of oil centrifuge

Construction of centrifuge:-
The centrifuge consists of a bowl which rotates on a vertical axis in an outer
casing. A 415V, 3 phase induction motor, mounted on the side of the casing drives the
bowl through a centrifugal clutch and a worm gear; a manually operated brake is
included on the worm shaft. The outer casing has a hinged lid which incorporates the oil
inlet and outlet connections, indications for flow and temperature and a priming water
supply. The base, which has an oil sump in which the worm gear runs, is mounted on
the purifier. The bowl, rotated by a vertical shaft, consists of a body and hood joined
with a locking ring. The body contains a stack of conical discs on a distributor, the top
disc has
a level ring which bridges the hub of the distributor, immediately above the level ring is
fitted a paring disc. The dirty oil inlet passes through the bowl hood gravity ring and
paring disc to the hollow distributor.
Working principle of centrifuge:-
The dirty oil from the main oil tank is supplied to the centrifuge through an inlet pipe.
This inlet line is provided with a manual gate valve for adjusting the capacity of
centrifuge, a Y type strainer. The inlet line supplies the oil to the suction of a feed pump.
A view glass provided before the pump enables the visual inspection of the oil flow. The
feed pump is built in with the centrifuge and is a gear pump. It is provided with an
integral pressure relief valve to prevent building up of excessive pressure in the
discharge side due to closure of any gate valve. When the pressure exceeds a preset
value, the relief valve. and discharges the oil to the pump suction itself. The suction and
discharge pressure can be read from the pressure gauge respectively and these gauges
are mounted on the local panel. The pump delivers oil to a heater tank through a check
valve. The oil is heated in this tank by means of hot water. The water is in turn heated
by electric heaters. The tank is provided with connections for water inlet, overflow, and
drain. A vent provided on top of the tank is useful to let out water vapor and to fill up
the tank quickly with water. A sight glass is also provided for checking the water level.
Three sections of immersion type electric heaters are used for heating the water. The
required number of heaters to be in service can be selected by means of a selector
switch provided in the control panel. In case of low water levels in the tank, a level
switch is useful to trip the heater. In case of high water temperature at 90 deg. C, a
temperature switch RT will trip the heaters. Two numbers of thermostats RT 101
provided the outlet of heater tank maintain the oil temperature by tripping the heaters
through relay R2. The heated oil is then fed to the centrifuge through a rotameter of
range 900 9000 liters per hour (lph).
The oil is purified in the centrifuge and the water gets separated. The water is
discharged to an antiflood tank and then drained through the tank drain. In case of
breakage of water seal inside the bowl, a high level switch provided in the Anti flood
tank gives an audible alarm and shuts off the oil supply by closing the solenoid valve in
the inlet oil line. The water seal has to be established on start-up by filling the bowl with
hot water; this can be supplied from the pump through the inlet connection on the hood.
The clean oil leaving the bowl rotates in the form of a ring around the paring disc which
is fitted with internal radial scoops. These scoops dip into the liquid ring converting its
kinetic energy into pressure to pump the oil through the annular space, between the oil
inlet tube and the housing, to the outlet connection.Ensure before operation of
centrifuge:-
1. Adequate water level in the heater tank is to be ensured. If the water level is
insufficient, the tank can be filled up by opening the make up valve.
2. The heater section is to be started half an hour earlier to the starting of the
centrifuge. This is for preheating the water.
3. The oil level in the centrifuge worm wheel housing is to be checked.
4. The frame hood of centrifuge has to be kept tight.
5. The main oil tank level is to be checked. The oil level and temperature of oil at inlet
to oil cooler are to be recorded.
6. All the bypass valves, drain valves and the sampling valves in the oil circuit are to
be kept in closed condition.
7. The inlet and outlet valves of the heater, PALL filter and the rotameter should be
kept open.
8. The gate valve in the inlet oil line is to be kept fully closed.
9. The gate valves in the oil line from the main oil tank to dirty oil header should be
fully closed. These valves should never be opened.
10. The gate valve in the inlet oil line to centrifuge from the clean oil chamber of the
main oil tank has to be kept closed and the gate valve from the drain oil chamber of the
main oil tank has to be kept OPEN.

What is voith/Hydraulic coupling and its working principle?

The main function of Hydraulic coupling is of controlling variable speed of equipment
by keeping the drive speed constant. Here the drive/motor speed is kept constant and
pump speed is varied as per requirement of discharge pressure and flow. This reduces
the power consumption particularly at part load/full load operation. The speed of pump
is varied by varying position of scoop.
IMAGE OF FLUID COUPLING
The essential parts to a fluid coupling:-
1) Pump impeller.
2) Aux. Lube oil pump.
3) Main lube oil pump.
4) Lube oil cooler.
5) Duplex filter.
6) Oil reservoir.
7) Scoop chamber.
8) Turbine wheel.
9) Working oil pump.
10) Scoop tube (adjustable).
11) Scoop tube control.
12) Working oil cooler.
You tube video of voith coupling
13) Oil circulation control valve.
Types of fluid coupling:-
a) Fixed speed- constant fill and Delay fill
b) Variable speed- Scoop controlled.
Working principle of voith coupling:-
The rotating coupled with the motor and operating fluid. The resultant centrifugal force
causes the fluid to flow outwards due to centrifugal force, where by the velocity of fluid
is increased. The flow of fluid into the runner takes place at the outer diameter, where
the energy is transmitted from the fluid to the runner. The fluid in the runner blade
chamber then flow inwards to the center & back into the impeller blade chamber. This
circuit is maintained by the centrifugal force difference resulting from the speed
difference between the runner & impeller. The time required to reach the full speed is
dependent on the inertia of the driven load, resistive torque, and the torque transmitted
by the coupling. The speed of the coupling is varied by varying the position of scoop.
Here the scoop is a cylindrical pipe with no of holes and act for draining oil from scoop
chamber. The scoop chamber is charged by a continuously running pump which delivers
oil from the integral sump below the coupling to the working compartment. The
working compartment is the chamber between the primary (impeller) & secondary
(runner) wheels. The oil level inside the working compartment determines the speed of
the output side of the coupling & depends upon the radial position of the scoop tube
located in the scoop chamber.
The output torque is equal to the input torque,defined as-
SLIP (%) = let n1=input speed
n2=output speed
n1 n2 slip(%)= ---------------- X 100
n1
All fluid couplings are normally designed to have a slip of 2% to 4%.
Advantage of voith coupling:-
1) The main advantage of fluid coupling is motor starts with minimum load.
2) No need of mechanical connection between the input and output elements.
3) Steeples speed variation in wide range obtained in scoop type fluid couplings.
4) Simple control of minimum to maximum load.
5) Effective for shocks, load fluctuations and torsional vibrations.
6) Economy for machine and drive design.